Transfer case leaking - How to Fix?? **WITH PIC**

[Chevy_Joe]

Well, I've determined there is a leak in my transfer case for my 2003 Chevy Silverado Z71 4x4.

 

I filled up the transfer case with fresh fluid, and it proceeded to leak out fluid overnight producing a puddle about the size of a coffee cup lid. I then cleaned off the case, but now it only leaks with a couple of drips through the night. I cleaned off the fluid residue from the transfer case to try and identify the source of the leak....apparently that's easier said than done... I checked the fluid level, and see that there is still plenty in there, so now I need to determine if this leak can be fixed.

 

I've read a few other forums about other Chevy and GMC owners who experience this issue (apparently I am not alone here!). I'm seeing residue in the two pocket areas and a drip at the tip of the case. Any advice on how to located the leak and fix this without paying a mechanic $1K? I've heard JB Weld can help, but where would I place the epoxy?

 

You can a pic of my case and the leak areas by looking at my post on another forum - http://www.gmtruckclub.com/forum/showthread.php/86715-Transfer-case-leaking-How-to-Fix-**WITH-PIC**?p=443832#post443832

[Chevy_Joe]

By the way, I see the drip, but do not see a hole anywhere. I've taken a pin light to it, and examined it pretty closely, but don't see anything. Any recommendations?

[gritz]

From the pic on that other forum, it looks like that's right below the rear output and overdrive. I would say to look there. If it's the seal on the output shaft, it's a pretty cheap, moderately easy fix. It's hard to tell from the pic. It's hard to see fresh atf anyway. You might try cutting a piece of paper to fit snug against the output housing and tape it flush against the case. If it's running from there, it may run down the paper instead of the tranfer case and help identify where it coming from. This is just an idea - hope this helps.